Method for laminating an overlay to verify a pattern or as a pattern

ABSTRACT

A method for forming an overlay ( 310 ); to be used to verify or form a folding die ( 300 ), embossing die ( 330 ), or rule die ( 320 ) comprising the steps of; creating an imaged receiver sheet ( 140 ) having an image ( 210 ), a first thermal print layer ( 224 ), and a support layer, laminating an imageless receiver sheet ( 160 ) having a second thermal print layer ( 228 ) and a second support layer ( 170 ), which is preferably clear with the imaged receiver sheet ( 140 ), thereby encapsulating the image ( 210 ) between the first thermal print layer ( 224 ) and the second thermal print layer ( 228 ); removing the first support layer ( 150 ); removing the second support layer ( 170 ); forming an overlay ( 310 ) having an electrostatic charge; to be used to verify or form a folding die ( 300 ), embossing die ( 330 ), or rule die ( 320 ).

CROSS REFERENCE TO RELATED APPLICATIONS

Reference is made to commonly-assigned copending U.S. patent applicationSer. No. 09/911,785, filed Jul. 24, 2001, entitled A SELF-ADHERINGIMAGE, by Roger S. Kerr, the disclosure of which is incorporated herein.

FIELD OF THE INVENTION

The present invention relates to preparing overlay's to be used toverify a pattern or as a pattern in the manufacturing process offolding, embossing or rule dies, using a lamination method that usespressure or heat and pressure to laminate media together.

BACKGROUND OF THE INVENTION

Pre-press proofing is a procedure that is used primarily by the printingindustry for creating representative images of printed material. In theprinting industry, pre-press proofs are used to check for color balance,control parameters, and other important image quality requirements,without the cost and time that is required to actually produce printingplates, set up a printing press, and produce an example of anrepresentative image, which results in higher costs and loss of profitsthat would ultimately be passed on to the customer. Once the pre-pressproofing process is complete. Product is printed and sometimes convertedto packaging for various items requiring folding, embossing or ruledies.

To create a pre-press proof, first, an original image is separated intoindividual color separations or digital files. The original image isscanned or separated into the three subtractive primaries and black.Typically, a color scanner is used to create the color separations ordigital files and in some instances, more than four color separations ordigital files are used. Although there are several ways used in theprinting industry to create a pre-press proof from color separations ordigital files, they are generally of three types. The first method beinga color overlay system that employs the representative image on aseparate base for each color, the image is then overlaid on each otherto create a pre-press proof. The second method uses a single integralsheet process in which the separate colors for the representative imageare transferred one at a time by lamination onto a single base. Thethird is a digital method in which the representative image is produceddirectly onto a receiver stock, from digital files.

The representative image to be laminated can be, but is not limited tobeing created on a commercially available Kodak image processingapparatus, depicted in commonly assigned U.S. Pat. No. 5,268,708 whichdescribes an image processing apparatus having half-tone color imagingcapabilities. The above-mentioned image processing apparatus is arrangedto form a representative image onto a sheet of thermal print media. Inthis process, dye from a sheet of dye donor material is transferred tothe thermal print media by applying a sufficient amount of thermalenergy to the dye donor sheet material to form the intended image. Theimage processing apparatus is comprised generally of a material supplyassembly consisting of a lathe bed scanning subsystem. The scanningsubsystem includes: a lathe bed scanning frame, translation drive,translation stage member, printhead, imaging drum, and media exittransports.

The operation of the image processing apparatus comprises: metering alength of the thermal print media (in roll form) from the materialsupply assembly. The thermal print media is then measured and cut intosheet form of the required length and transported to the imaging drum,registered, wrapped around, and secured onto the imaging drum. Next, alength of dye donor material (in roll form) is also metered out of thematerial supply assembly, then measured and cut into sheet form of therequired length. It is then transported to the imaging drum and wrappedaround the imaging drum utilizing a load roller which is described indetail in commonly assigned U.S. Pat. No. 5,268,708. By wrapping, it issuperposed in the desired registration with respect to the thermal printmedia (which has already been secured to the imaging drum).

After the dye donor sheet material is secured to the periphery of theimaging drum, the scanning subsystem or write engine provides theimaging function. This imaging function is accomplished by retaining thethermal print media and the dye donor sheet material on the imaging drumwhile it is rotated past the printhead. The translation drive traversesthe printhead and translation stage member axially along the axis of theimaging drum, in coordinated motion with the rotating imaging drum.These movements combine to produce the intended image on the thermalprint media.

Once a representative image has been formed on the thermal print media,the dye donor sheet material is then removed from the imaging drum. Thisis accomplished without disturbing the thermal print media that isbeneath it. The dye donor sheet material is then transported out of theimage processing apparatus by means of the material exit transport.Additional dye donor sheet materials are sequentially superimposed withthe thermal print media on the imaging drum. These materials are thenimaged onto the thermal print media previously mentioned until therepresentative image is completed and transferred onto the thermal printmedia. The completed representative image formed thereon is thenunloaded from the imaging drum and transported by the receiver sheetmaterial exit transport to an exit tray in the exterior of the imageprocessing apparatus.

After a representative image has been formed on the thermal print mediaas previously described, it is then transferred to a receiver stock suchthat the pre-press proof is representative of an image that would beprinted on a printing press. A Kodak Laminator as described in U.S. Pat.No. 5,478,434 can be used to bond or laminate the representative imageas part of a pre-press color proofing system but this invention is notlimited to the use of this device. U.S. Pat. No. 5,203,942 describes aKodak Laminator that employs a lamination/de-lamination system asapplied to a drum laminator, and pending U.S. patent application Ser.No. 09/676,877 describes a Kodak Laminator that employs endless beltsincorporated into the lamination apparatus. For the purpose of thispatent application the laminator described in pending U.S. patentapplication Ser. No. 09/676,877 will be used. It should be noted thatthe present invention described in this disclosure is not limited to aKodak Laminator or to the type of laminator reference above.

Generally laminating a pre-press proof comprises a two pass, laminationprocess. For the first step, a sheet of pre-laminate, which has apre-laminate support layer and a thermal print layer, encapsulation orprotective layer, is placed on top of a receiver sheet, which is alsocalled “receiver stock” in the industry. This construction of multiplelayers is a lamination sandwich, which is fed into the laminator. Oncethe lamination sandwich exits the laminator the pre-laminate supportlayer is peeled away from the now pre-laminated receiver stock.

For the second pass, the imaged thermal print media with therepresentative image formed thereon is placed on the pre-laminatedreceiver stock with representative image face down on the pre-laminatedreceiver stock and fed into the laminator. After the lamination sandwichhas exited the laminator, the thermal print support layer is peeledaway, leaving the completed pre-press proof simulating an image producedon a printing press.

While the above-described lamination method works well for both laserthermal and inkjet pre-press proofs, there exists a need for an overlayto be used as a pattern or to verify a pattern in the manufacturingprocess of folding, embossing or rule dies used in the packagingindustry to convert printed material into packaging of different shapesand sizes for a variety of products.

SUMMARY OF THE INVENTION

The present invention provides a method of forming an overlay to be usedas a pattern or to verify a pattern in the manufacturing process offolding, embossing or rule dies. The novel methods of the presentinvention are preferably for forming an overlay to be used as a patternor to verify a pattern in the manufacturing process of folding,embossing or rule dies, but not limited to with an image resolution ofbetween about 1000 and 4000 dpi and most preferably having a resolutionof about 1800 to 3000 dpi. The overlay can be a monochrome image ormulticolor image. The image receiver sheet support layers can comprise arelease layer, an aluminized layer, and a support base or combinationthereof, or just a support base. The base can be made from polyester,polyethylene, or other materials well known in the art. The thermalprint layers have a thickness ranging from 1 micron to 75 microns, andmore preferably from 1 to 25 microns.

The invention relates to a method for forming an overlay to be used as apattern or to verify a pattern in the manufacturing process of folding,embossing or rule dies comprising the steps of: creating an imagedreceiver sheet having an image, a first thermal print layer, and asupport layer; laminating an imageless receiver sheet having a secondthermal print layer and a second support layer, which is preferablyclear with the imaged receiver sheet, thereby encapsulating the imagebetween the first thermal print layer and the second thermal printlayer; removing the first support layer forming an overlay; using saidoverlay having an image, preferably using an electrostatic charge; toaid in the manufacture of folding, embossing or rule dies.

The invention also relates to a method for forming an overlay to be usedas a pattern or to verify a pattern in the manufacturing process offolding, embossing or rule dies comprising the steps of: creating animaged receiver sheet having an image, a first thermal print layer, anda support layer; laminating an imageless receiver sheet having a secondthermal print layer and a second support layer, with the imaged receiversheet, thereby encapsulating the image between the first thermal printlayer and the second thermal print layer; removing the first supportlayer; removing the second support layer forming an overlay; using saidoverlay having an image, preferably using an electrostatic charge; toaid in the manufacture of folding, embossing or rule dies.

The invention also relates to a method for forming an overlay to be usedas a pattern or to verify a pattern in the manufacturing process offolding, embossing or rule dies comprising the steps of: creating animaged receiver sheet having an image, a first thermal print layer, anda support layer; laminating a plastic sheet, which is preferably clearwith the imaged receiver sheet, thereby encapsulating the image betweenthe first thermal print layer and the second thermal print layer;removing the first support layer forming an overlay; using said overlayhaving an image, preferably using an electrostatic charge; to aid in themanufacture of folding, embossing or rule dies.

The invention, its objects and advantages, will become more apparent inthe detailed description of the preferred embodiments presented below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing a laminator known in the relatedart used with the present invention.

FIG. 2 is a schematic right side elevation of the laminator known in therelated art of FIG. 1.

FIG. 3 is a block diagram of the present invention showing an embodimentof a method for forming an overlay to be used as a pattern or to verifya pattern in the manufacturing process of folding, embossing or ruledies.

FIG. 4 is a block diagram of the present invention showing a anotherembodiment of a method for forming an overlay to be used as a pattern orto verify a pattern in the manufacturing process of folding, embossingor rule dies.

FIG. 5 is a block diagram of the present invention showing a anotherembodiment of a method for forming an overlay to be used as a pattern orto verify a pattern in the manufacturing process of folding, embossingor rule dies.

DETAILED DESCRIPTION OF THE INVENTION

The present description will be directed, in particular, to elementsforming part of, or cooperating more directly with, an apparatus inaccordance with the present invention. It is to be understood thatelements not specifically shown or described may take various forms wellknow to those skilled in the art. For the sake of discussion, but notlimitation, the preferred embodiment of the present invention will beillustrated in relation to a laminating apparatus for making pre-pressproofs.

Referring to the drawings wherein like reference numerals representidentical or corresponding parts throughout the several views. Referringto FIG. 1, there is shown a perspective view of laminator 10 asdescribed in U.S. patent application Ser. No. 09/676,877. The laminatorhas an: entrance table 20, exit table 30, entrance slot 40, pressurelever 50, top cover 60, right side cover 70, left side cover 80, controlpanel 90, and lamination base 100.

FIG. 2 is a schematic right side elevation of the laminator of FIG. 1showing endless belts 110 with upper lamination roller 120 and lowerlamination roller 130 which convey media to be laminated through thelaminator 10. Media to be bonded or laminated pass between the endlessbelts 110. Upper lamination roller 120 and lower lamination roller 130provide heat and pressure to laminate the desired media together. Thisconfiguration with upper lamination roller 120 and lower laminationroller 130 is known in the art as a “straight-through” lamination.Although the illustrated embodiments show both the upper laminationroller 120 and lower lamination roller 130 as heated rollers, it alsoshould be recognized and only upper lamination roller 120 or lowerlamination roller 130 may be heated. It is further recognized that bothupper lamination roller 120 and lower lamination roller 130 do not haveto be heated for cold lamination applications to work within the scopeof this invention.

FIG. 3 is a block diagram outlining a method for forming an overlay 310preferably having a surface energy charge, to be used as a pattern or toverify a folding die 300, embossing die 330 or a rule die 320, whereinsaid overlay 310 is formed by the method comprising the steps of:creating an imaged receiver sheet 140 comprising an image 210, a firstthermal print layer 224, and a first support layer 150 having; a supportbase 230, an aluminized layer 240, and a release layer 250 it should benoted that first support layer 150 may be comprised of several layers ora single support base 310. Laminating said imaged receiver sheet 140 toan imageless receiver sheet 160 having a second thermal print layer 228,and a second support layer 170, which is preferably clear, therebyencapsulating the image 210 between the first thermal print layer 224and the second thermal print layer 228; removing the first support layer150, resulting in an overlay 310, to be used as a pattern or to verify afolding die 300, embossing die 330 or a rule die 320.

FIG. 4 is a block diagram outlining a method for forming an overlay 310preferably having a surface energy charge, to be used as a pattern or toverify a folding die 300, embossing die 330 or a rule die 320, whereinsaid overlay 310 is formed by the method comprising the steps of:creating an imaged receiver sheet 140 comprising an image 210, a firstthermal print layer 224, and a first support layer 150 having; a firstsupport base 234, a first aluminized layer 244, and a first releaselayer 254 it should be noted that first support layer 150 may becomprised of several layers or a single support base 310. Laminatingsaid imaged receiver sheet 140 to an imageless receiver sheet 160 havinga second thermal print layer 228, and a second support layer 170 itshould be noted that second support layer 170 may be comprised ofseveral layers or a single support base 310, having; a second supportbase 238, a second aluminized layer 248, and a second release layer 258it should be noted that second support layer 170 may be comprised ofseveral layers or a single support base 310, thereby encapsulating theimage 210 between the first thermal print layer 224 and the secondthermal print layer 228; removing the first support layer 150, removingthe second support layer 170; resulting in an overlay 310, to be used asa pattern or to verify a folding die 300, embossing die 330 or a ruledie 320.

FIG. 5 is a block diagram outlining a method for forming an overlay 310preferably having a surface energy charge, to be used as a pattern or toverify a folding die 300, embossing die 330 or a rule die 320, whereinsaid overlay 310 is formed by the method comprising the steps of:creating an imaged receiver sheet 140 comprising an image 210, a thermalprint layer 220, and a support layer 145 having; a support base 230, analuminized layer 240, and a release layer 250 it should be noted thatsupport layer 145 may be comprised of several layers or a single supportbase 310. Laminating said imaged receiver sheet 140 to a plastic sheet260 which is preferably clear, thereby encapsulating the image 210between the thermal print layer 220 and the plastic sheet 260; removingthe first support layer 150, resulting in an overlay 310, to be used asa pattern or to verify a folding die 300, embossing die 330 or a ruledie 320.

The thermal print layer 220, first thermal print layer 224, and thesecond thermal print layer 228 of the above described methods forforming an overlay 310 preferably has a thickness ranging from 1 micronto 75 microns, and most preferably is a thickness ranging from 1 to 25microns and are made of a Butvar material, but could be a polyacrylatematerial, or other materials known in the art.

The image 210 of the imaged receiver sheet 140 of the above, describedmethods for forming an overlay 310 preferably has a resolution ofbetween about 1000 and about 4000 dpi, and most preferred the imagereceiver sheet 140 has a resolution of between about 1800 and about 3000dpi.

In alternative embodiments, the second support layer 170 is clear.

In one embodiment, the material for the thermal print layer 220, firstthermal print layer 224, and second thermal print layer 228encapsulating the image 210 is most preferably a Butvar having the samethickness on both sides.

In alternative embodiments, the encapsulating material of the thermalprint layer 220, first thermal print layer 224, and second thermal printlayer 228 is contemplated as a polyacrylate, Butvar, or other materialwell known in the art. Whether a polyacrylate, Butvar, or other materialwell known in the art, the thickness of the thermal print layer 220,first thermal print layer 224, and second thermal print layer 228 can beidentical or disparate to each other.

In performing the methods described above, it is considered within thescope of the invention that the lamination temperatures ranges up toabout 160° C. and preferably, 130° C. for dye-based and pigment-basedimages. Pressures for the methods described above are around 80 psi.

In embodiments of the invention described above, image 210, can begenerated by laser thermal, inkjet or combinations thereof, or othermethods well known in the art.

In embodiments of the invention described above, the imaged receiversheet 140 can have a monochrome image or multicolor image.

In alternative embodiments the first support layer 150 can comprise asupport base 230, first support base 234, and second support base 238;an aluminized layer 240, first aluminized layer (not shown), and secondaluminized layer (not shown); a release layer 250, first release layer254, and second release layer 258 or combinations thereof.

The support base 230, first support base 234, and second support base238 can be made of polyester, polyethylene, combinations of the twomaterials, or other materials well known in the art.

The invention has been described in detail with particular reference tocertain preferred embodiments thereof, but it will be understood thatvariations and modifications can be effected within the scope of theinvention.

Parts List

10. Laminator

20. Entrance table

30. Exit table

40. Entrance slot

50. Pressure lever

60. Top cover

70. Right side cover

80. Left side cover

90. Control panel

100. Lamination base

110. Endless belts

120. Upper lamination roller

130. Lower lamination roller

140. Imaged receiver sheet

145. Support layer

150. First support layer

160. Imageless receiver sheet

170. Second support layer

190. Protective layer

210. Image

220. Thermal print layer

224. First thermal print layer

228. Second thermal print layer

230. Support base

234. First support base

238. Second support base

240. Aluminized layer

244. First aluminized layer

248. Second aluminized layer

250. Release layer

254. First release layer

258. Second release layer

260. Plastic sheet

300. Folding Die

310. Overlay

320. Rule die

330. Embossing die

What is claimed is:
 1. A method of using an overlay to verify the shapeof a die, comprising the steps of: a) forming an overlay by the methodconsisting of the steps of: i) creating an imaged receiver sheet havingan image comprising a first thermal print layer; and a first supportlayer; ii) laminating an imageless receiver sheet having a secondthermal print layer and a second support layer with said imaged receiversheet, thereby encapsulating said image; iii) removing said firstsupport layer forming an overlay having an electrostatic charge; and b)using said overlay to verify or form a rule die.
 2. The method of claim1 wherein said first support layer comprises a first support base, afirst release layer, and a first aluminized layer.
 3. The method ofclaim 2 wherein said first support base comprises a member of the group:polyester, polyethylene, and combinations thereof.
 4. The method ofclaim 1 wherein said thermal print layer comprises Butvar.
 5. The methodof claim 1 wherein said thermal print layer comprises a polyacrylate. 6.The method of claim 1 wherein the laminating temperature is about 120°C. for dye based image.
 7. The method of claim 1 wherein the laminatingtemperature is less than about 120° C. for pigment based images.
 8. Themethod of claim 1 wherein the laminating pressure is performed at up to80 psi.
 9. The method of claim 1 wherein the image is an inkjetgenerated image.
 10. The method of claim 1 wherein said imaged receiversheet comprises a monochrome image.
 11. The method of claim 1 whereinsaid imaged receiver sheet comprises a multicolor image.
 12. The methodof claim 1 wherein said second support layer is a flexible clearmaterial.
 13. The method of claim 1 wherein said thermal print layerseach has a thickness of between 1 and 75 microns.
 14. The method ofclaim 1 wherein said imaged receiver sheet has a resolution of betweenabout 1000 and about 4000 dpi.
 15. The method of claim 1 wherein saidimaged receiver sheet has a resolution of between about 1800 and 3000dpi.